11-Axis Automatic Lathe and Turn-Mill with Bevel Gear Capability

August 1, 2016

The new TRAUB TNL32-11 sliding/fixed headstock automatic lathe has a headstock moving in the Z-axis, an upper and identical lower turret with X-, Y- and Z-axes, and a counter spindle movable in the X and Z directions.

The machine offers a new front working attachment which sits on an additional cross-slide moving in the X- and Z-axes, providing the user with further freely positionable tools and enables the use of up to three tools simultaneously and independently of each other. "The 11-axis machine saves machining time, especially for components with a high proportion of drilling," said a company spokesperson.

In addition to the two linear X- and Z-axes, the front working attachment features a CNC circular axis. By the interpolation of the rotary axis with the X-axis and the C-axis of the main spindle, the front working attachment can also be used in the Y direction using an interpolated Y-axis. "When a drilling tool needs to be corrected to exact center, the necessary corrections can be simply performed via the CNC controller," said the spokesperson. "That can be helpful with small parts which react with great sensitivity to even minimal offset errors."

The front working attachment makes eight additional tool stations available. Four of them are used to mount fixed tools, the other four are for live tools.

There is also a station for a workpiece gripper which can unload a machined workpiece from the counter spindle. "While the finished workpiece is discharged from the counter spindle, the next part can be machined with two tools at the main spindle," said the spokesperson.

With an output of up to 3.4 kW and a maximum speed of 12,000 RPM, the tool drive in the front working attachment is designed for productivity and high power. The toolholders are robust and stiff with a mounting shank diameter of 36 mm. Individually controllable coolant pressure of up to 80 bar is available at every station. One live station can be used as a deep-hole drilling station with a coolant supply up to 120 bar. The front working attachment can also be used as a tailstock when producing long components.

"In addition to the advantages of the front working attachment, the TRAUB TNL32-11 offers the many other benefits of the entire TNL series," said the spokesperson. "The work area is easily accessible to the operator due to its high and wide sliding door, simplifying set-up and changeovers. A large inspection window allows the operator to keep a close eye on the machining process. The long Z travel of the headstock means the machine can easily be used for sliding or fixed headstock turning without compromises in less than 15 minutes."

Tool turret indexing is performed using an NC rotary axis that controls movement via an internally meshing planetary gear. This allows the turret to be indexed to any position without requiring a mechanical locking mechanism. The free positioning of the turret makes multiple-tool assignment possible on each station.

"Another highlight is the `Dual Drive', consisting of two drive trains integrated within one turret," said the spokesperson. "This patented drive solution reduces non-machining time and thus also machining times per piece. While one tool is in use, the tool intended for the next work step can be accelerated up to the desired speed during main time and is immediately available at full speed after the turret indexing operation."

"Jerky accelerations and delays that were previously unavoidable when reducing auxiliary processing times are now prevented," said the spokesperson. "In addition, toolholder wear is reduced due to the lower acceleration values. Even with live tools, chip-to-chip times are around just 0.3 seconds."

INDEX G220 Turn-Mill Center

The new INDEX G220 Turn-Mill Center includes a motorized 5-axis 18,000 RPM (max.) milling spindle and a tool turret with Y-axis, providing machining flexibility for turning and milling complex parts in a single set-up from bar stock up to 90 mm diameter, chuck diameter 210 mm. Distance between spindles is 1,280 mm, maximum turning length is 1,000 mm. "Users in the precision parts industries including automotive, aerospace and mechanical engineering will benefit from the machine's high-accuracy and its ability to complete a part in a single set-up," said the spokesperson.

The cutting method is similar to the Klingelnberg gear generating method and makes use of the G220's Y-B- axis provided in the milling head. "The process is ideal for smaller, .6 to 4 module size bevel gears as it can produce high quality gears, front and back, faster than conventional bevel gear machines," said the spokesperson. "The G220 can also produce other types of gears as well as other complex precision parts due to its versatility."

The fluid-cooled, identical main and counter spindles provide power of 31.5/ 32 kW (100%/40%), a torque of 125/ 170 Nm and a maximum speed of 5,000 RPM.

The fluid-cooled five-axis motorized milling spindle (power 11 kW, torque 19/30 Nm, speed up to 18,000 RPM) has hydrostatic bearings in the Y/B-axes. The stable circular guide is designed for rigidity and damping. The Y-axis features a +/-80 mm stroke, the B-axis driven directly by a torque motor has a swivel range of -50 to +230 degrees. With a large travel distance in the X-direction, machining at up to 30 mm below the turning center height is possible.

The motorized milling spindle operates using a one or optionally two-row tool chain magazine which features space for 70 or 140 tools (HSK-A40). The double-row tool magazine enables set-up during machining time.

A tool turret is located in the lower part of the machine and can accommodate VDI 25 and VDI 30 tool mountings in 18 or 12 stations respectively, all of which can be equipped with individually driven tools (power 6 kW, torque 18 Nm, speed 7,200 RPM).

The compact machine features a CNC-controlled programmable gantry-type removal unit for finished workpieces. It can unload remnants from the main spindle as well as finished parts from the counter spindle. "The G220 offers a generous work area, so operators have easy access to the main and counter spindles, the turret and the motorized milling spindle, as well as the operating panel," said the spokesperson.

"The G220 presents a particular highlight when it comes to user friendliness and process reliability with the latest generation of the INDEX C200 SL controller," said the spokesperson. Based on the Siemens Sinumerik 840D sl (solution line), it features an 18-inch touchscreen. The operating features a second input which INDEX uses for its optional Virtual Machine (VM) program simulation. By pressing a button, the operator can switch to "VM on Board" and make use of simulation, irrespective of current machine operations.

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